hydropower technology r&d at doe's national laboratories · columbia technical approach:...
TRANSCRIPT
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Hydropower Technology R&D at DOE’s National Laboratories
Brennan Smith ORNL
May 4, 2017
Water Power Technologies Office
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Panel 4 – Hydropower Technology
Outline 1. Hydropower Fleet Intelligence 2. Systems and Components for Standard Modular Hydropower 3. Enabling Technologies
– Manufacturing and Materials – High Performance Computing – Big Data Analytics
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Hydropower Fleet Intelligence
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Improving and Valuing Flow Measurement
• Short converging intakes represent 10% of domestic capacity
• No code-accepted methods guaranteeing accuracy of flow measurement.
• Flow measurement uses o verifying performance guarantees o detecting efficiency degradation o assuring water delivery o assuring multi-unit efficiency
Measurement accuracy improves unit performance characteristics Annual Energy and Revenue Benefits of Increased Accuracy Costs of
Technology Deployment to
Implement Accuracy
Improvement
Historical dispatch provides context for how much efficiency matters
• Data-driven decisions on flow measurement upgrades
• Installed cost targets for new flow measurement technology
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Scheduling Analysis and Optimization
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Performance characteristics for multiple unit types
Plant performance
Annual Energy Production
Comparison to Idealized Production
Condition & Performance Data
Analyses with Hydroplant Performance Calculator
Plant actual compared to ideal
Greater efficiency more start/stops
Ramp rates from sub-hourly data
Exemplary Case Study • Historical plant dispatch, water, and head are preserved • Moving toward a standardized analysis template with visualization • Deviations from ideal have causes that can/should be understood • All types of data are stove-piped and time-consuming to export from
plant systems—there needs to be a better way • Correlation and cause/effect between dispatch and O&M costs are not
obvious—subtle linkages may be impossible to detect without more granular data
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Water Quality Scheduling and Optimization
Columbia Technical Approach: develop a simplified physics-based mass-transfer model for total dissolved gas uptake and transport, to be implemented in Decision Support Systems (DSS) and forecasting applications
Methods: • Partition river system into uptake and transport regimes
(see figure on top right) • For uptake region, develop site neutral TDG representative
equations based on the main physical processes of TDG production and mixing:
• Air entrainment during the plunging of spill water in the tailrace
• Entrainment of powerhouse water into the spillway region (see figure on bottom right)
• For transport region, analyze time lag of TDG plume between reservoirs Approach Uniqueness:
• The representation of complex river system processes through a simplified mathematical approach enables a straight forward implementation in DSS applications, reducing computational overhead without a decrease in predictive accuracy
• Contrary to conventional TDG management techniques, a hydropower scheduler can now quickly and accurately simulate multiple operational scenarios and optimize real-time and future schedules to minimize TDG levels while still meeting hydropower objectives
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Water Quality Scheduling
N linked, calibrated W2 models
Water quality & hydrodynamics
M1
M2
M3
M4 M5
MN
W2 Model Outputs (time series)
Model Inputs
Database
Model order-reduction tool -Assumptions -Limitations
-Methodology
-Water elevations -Temperature
-DO
-Calibration parameters -Meteorological data
Match with
minimum error
Tool Outputs
Calibrated reservoir models can be used to “train” the new model once.
Decision makers can quickly model various scenarios, obtain accurate outputs, and optimize operations.
Optimization Framework
Cumberland Model Overview
Uniqueness: Development of the first multiple reservoirs system high fidelity model reduction that can be used in operational scheduling, planning, and decision making by hydropower operators
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Expert opinion elicitation, failure event data, and operating history are combined to discern reliability and risk for a specific component and unit.
Visualization of Operating Pattern and History
Estimated Risk as Function of Operating Hours and Starts
Powertrain Failure Risk Modeling - ORNL
Target Product Phasing: Component Failure Model – FY17 Powertrain Failure Model – FY17-18 Unit Outage Model – FY18? Fleet-Wide Risk Minimization Model - ??
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Predictive Maintenance Optimization - PNNL • Challenge
– Nationally, 75% of installed hydropower capacity is located at facilities that are 50 years or older
• Solution – Predictive Maintenance
• improve correlation of operations and situational data to current and future states of hydroelectric turbines
• extend hydropower unit life and increase unit reliability.
• Impact – Integrated decision support tool for asset lifetime
management that: • Utilizes real-time data for monitoring condition
of critical FCRPS assets and enables calculation of remaining service life estimates (along with confidence bounds) for monitored assets;
• Performs integrated risk analyses to predict changes in operational risk based on the monitored condition of assets and enables cost-benefit assessment for predictive maintenance scheduling;
• Provides potential inputs into operational decision making for plant control, by enabling what-if assessments that incorporate real-time component condition and predictive failure probabilities
10 10 Managed by UT-Battelle for the U.S. Department of Energy
Patented Electrical Signature Analysis (ESA) developed by ORNL’s Measurement Science and Systems Engineering Division
Frequency analysis of helicopter tach generator signals identifies gear train component signatures and anomalies
• electric motors and generators act as transducers—no new sensors! • current and voltage data collected at a safe, convenient location in field apps • device-specific development accelerated by comparative vibration testing • Can work with other condition and performance monitoring technology.
Condition Monitoring Technology - ORNL
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Big Data for a Sustainable Energy System
Sensing and monitoring
Develop low-cost devices that can provide increased
visibility to the energy system
Data Management
Ensure data accuracy, integrity, and
trustworthiness at appropriate sampling rates
based on efficient architecture for rapid
authorization, integration, and retrieval
Modeling and Simulation
Developed advanced models (dynamic models) used in
understanding implications on the energy delivery
system
Data Analytics & Visualization
VERDE system: Providing analysis based on advanced models, data analytics, and
high performance computing
Utilize the vast Laboratory resources to address challenges of limited system visibility, managing data proliferation and turning data into actionable information
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Sensor development & big data analysis and visualization
• Developing low cost sensors for the electric system.
- Near-term: Increase accuracy of synchrophasor technology
- Longer-term effort: develop low-cost systems for asset monitoring
- Partnering with industry: National Instruments, Eaton, SmartSense
• Data analytics & visualization: EAGLE-I
- Near-term: Predictive analytics for forecasting infrastructure and population at risk during extreme weather events
- Data management & data repository
- Users are from DOE, DHS, NGA, DOD, and others
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Unit Intelligence
Facility Intelligence
Hydrosystem Intelligence
Hydropower Fleet Intelligence
Energy-Water Infrastructure Intelligence
Knowledge Alignment Correlation Causation Patterns & Signals
Reliability Data
Maintenance Data
Condition Assessment
Data
Condition Monitoring
Data
Cost Data
Meteorological & Hydrologic
Data Safety Data Operations & Dispatch Data
Electric Power System Data
Data knowledge intelligence decisions Reliability Resilience
Value Flexibility
Data, Information, Experience
GADS
e.g., Maximo
e.g., HydroAMP
e.g.. Vibrosystm, MCM
EUCG, Navigant
e.g., WaterView OpEx
A Vision for Hydropower Fleet Intelligence ORNL
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Systems and Component Solutions for
Standard Modular Hydropower
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Standard Modular Hydropower (SMH)
Framework for classifying potential SMH sites in terms useful for specifying module
design requirements and constraints
EXEMPLARY DESIGN
WATERSHED STREAM
SITE ACCESS
Hydrology Geomorphology Ecology
Fluvial Hydraulics Aquatic Ecology Water Quality Streamscape Multipurpose Use
INTERCONNECTION AVAILABILITY
SITE CLASSIFICATION Specify the design objectives, requirements,
constraints, and performance that aligns module functions with natural stream functions
Sustained, Predictable,
Acceptable, and Efficient
Outcomes
Environmental Enhancement
Cost Reductions Standard Designs
Standard Review Plans Standard Site Permitting
Environmental Certifications
Testing Codes and Standards
Safety Certifications Workforce Training
TESTING & VALIDATION CAPABILITY Full scale validation of performance,
safety, reliability, and techno-economic feasibility of SMH technologies
𝑭𝑭𝑭𝑭𝑭𝑭𝑭𝑭
𝑯𝑯𝑯𝑯𝑯𝑯𝑯𝑯
GENERATION MODULES
PASSAGE MODULES
FOUNDATION MODULES
𝑭𝑭
SIMULATION & MODELING CAPABILITY Simulating and optimizing SMH designs,
reducing costs, and predicting and validating reduction of environmental impacts
Stakeholder Elicitation
and Participation
Resource Assessment and Analyses
SMH Research Pillars
Environmental Hydraulic
Mechanical Structural Electrical Biological
Coupled Systems Cost
Performance Safety
Reliability Rapid Prototyping
Manufacturing
Low-Cost
Low-Impact
hydropower.ornl.gov/smh
16 16 Managed by UT-Battelle for the U.S. Department of Energy
ORNL Power Electronics & Electric Machinery Expertise
• 35 staff researchers, 700 sq meters of laboratories • Designated as a National User Facility, encouraging
collaborative efforts between the PEEMRC, industry, and academia (including proprietary work)
• World-wide reputation is supported by awards, patents, publications, and recognition by professional societies, academia, industry and DOE.
• 100 HP and 400 HP test dynamometers • Power quality and utility interconnection research • Advanced electric machine technologies
− Permanent magnet (axial and radial gap) − Switched reluctance − Induction (novel designs and rotor bar
technology) − DC machines − Superconducting generators − Variable speed drives
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Hydropower Unit and Integration Testing
• Evolving grid needs evolving hydropower systems that can adjust smartly • Several novel components that include advanced power converters, governor and
exciters need to be tested under real world grid and flow conditions • Real-time Hardware-In-the-Loop based testing is next best to actual field testing
• Complimentary testing protocols between controls and power hardware is necessary to ensure interoperability and interconnection
• Iterative enhancement leading to modularity of design, operation, and maintenance • Truly ‘plug-and-play’ similar to other renewable technologies
• Frequency, voltage, ride thru settings, market interface of hydropower generators and power converters that are difficult to model and test in field can be assessed
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ORNL Sustainable Electricity Testing Capabilities Conductors Cables Distribution High Voltage
• Advanced conductor
testing: accelerated aging, remaining life, coatings and auxiliary equipment
• High-current (5,000A), low-voltage (400V) dc induces thermal testing (300 C) 2400 feet conductors
• Cables: up to 50 m • Test capabilities up to 80kA; three
phase to 4kA • DC currents to 25 kA; • Tested Inherent HTS fault current
limiter: 60kA fault current limited to 32kA in one cycle.
• DECC facility provides • Smart inverters, distributed
systems, microgrid • AMI Interoperability test-bed • Protection schemes for renewable
integration • Intelligent buildings • EV, PHEV and energy storage
• Electrical insulation • High voltage: 500-kV impulse
generator • Partial discharge analysis • Ultra-high-speed streak/framing
camera • Gas chromatography mass
spectrometers
MVA pulse transformers for fault-current limit testing
Electrical power feeder to ORNL’s Cable Test Facility. The 13.8 kV power is fed directly to two 5.1 MVA transformers for fault current testing of electrical grid devices.
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Real-Time Digital Simulation HIL Distributed Communications and Controls Laboratory
Open-Source Communications and Controls Architecture
Complete System-Level Efficient and Interoperable Solution for Microgrid Integrated Controls (CSEISMIC)
Microgrid Switch Controls Inverter Controls
Photovoltaic System
Software Defined Intelligent Grid Research Integration
Rack Mounted Systems
ORNL Grid Testing Capabilities
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Ground-Level Integrated Diverse Energy Storage (GLIDES) System
ORNL INVENTION: Ayyoub. M. Momen, O. Abdelaziz, K. R. Gluesenkamp, and E. A. Vineyard, “High-Efficiency Ground-Level Pumped-Hydro Electricity Storage,” Invention Disclosure 201303175, DOE S-124,766.
Key advantages Simple, low cost (expected to be at lower
cost than batteries) Dispatchable
Accepts heat and electricity as inputs Scalable Round-trip efficiency>70% Quick or slow charge/discharge time
Objective: Develop a unique, low-cost, high round trip efficiency storage technology for a) small scale building applications b) large scale modular pump hydro storage.
An ORNL innovative technology solution for the Urban EWN
ORNL POC: Ayyoub Momen
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Supporting Technologies and Science
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Advanced Materials Applications - PNNL • Challenge
– There are high direct costs associated with repair and replacement of cavitation damaged turbine blades.
• Solution – Cold Spray
• A method that works by shooting metal particles at very high speeds into the damaged area.
• The impact energy created by these high speeds produces a solid-state weld between the particle and the turbine surface.
• Melting and material degradation common in current welding repair techniques does not occur and hydropower turbine blades are left in their original shape.
• Cold spray repair is capable of depositing materials with hardness and wear resistance that match or exceed that of the turbine base metal—meaning cold spray repairs should produce superior performance in repaired turbines.
– Friction Stir Processing • Similar to Cold Spray, these are other low energy processes that
can be used to join, repair or improve the performance of hydropower components by avoiding the melt phase and creating refined microstructures.
• Creates novel compounds that can be stronger and longer-lasting than the base metal giving components new life or making new components cheaper by only requiring high performance materials at stress and wear points.
• Impact – Materials science applications such as Cold Spray, may reduce the cost
of deploying new hydropower or extend the lifespan of existing hydropower projects.
Francis turbine: cavitation damage and old repairs with stainless steel welding.
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Superhydrophobic Coatings Technology - ORNL
Anti-icing coatings on power lines, and insulators
• Nano-textured amorphous silica (sand) • Very high contact angle (160º to 175º)
Anti-biofouling
http://www.ornl.gov/adm/partnerships/tech/superhydrophobic/docs/ABCs_of_Superhydrophobic.pdf
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Science to Application
Carbon Fiber Technology Facility Focused on demonstrating the scalability of low-cost carbon fiber
• 42,000 ft2 facility, equipped using $34.7M in DOE funding
– November 2011: Facility occupancy
– October 2012: Installation complete – Q4 2012: Start-up testing/commissioning
– Q1 2013: First fibers off the line (using “standard” PAN precursor material)
• Production capacity: 25 tons/year of fiber from multiple precursors in various forms
• Leverages and promotes industry partnerships
• Links bioscience to engineering science
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Big Area Additive Manufacturing (BAAM) An Example of ORNL Capability
• The Shelby was printed at the DOE-Manufacturing Demonstration Facility at ORNL using a 20% carbon fiber reinforced ABS material and has a Class A Surface finish.
• The design allows integrated components to be tested and enhanced in real time, improving the use of sustainable, digital manufacturing solutions
DOE Manufacturing Demonstration Facility at ORNL